Sealed beverage basket and method of making

ABSTRACT

A basket for holding beverage grounds includes a frame. The frame includes a continuous rim that defines an opening at a top of the frame, a bottom portion that is closed, and a plurality of spaced apart ribs that extend from the rim to a peripheral edge of the bottom portion. The bottom edge, plurality of ribs and rim define a plurality of openings that facilitate fluid flow. A filter material is positioned in the plurality of openings. A removable outer sleeve is formed on an outside surface of the frame. The outer sleeve is configured to cover at least the plurality of openings to thereby provide an air-tight seal within the frame.

RELATED APPLICATIONS

This application claims the benefit of the filing date under 35 U.S.C.§119 to U.S. Provisional Application No. 61/538,623, filed Sep. 23,2011, and is also a continuation-in-part of U.S. application Ser. No.13/191,219, filed Jul. 26, 2011, which is a continuation-in-part of U.S.application Ser. No. 12/889,144, filed Sep. 23, 2010, which claims thebenefit of the filing date under 35 U.S.C. §119 to U.S. ProvisionalApplication No. 61/246,796, filed Sep. 29, 2009, the contents of all ofwhich are hereby incorporated by reference in their entirety.

BACKGROUND

Single serve beverage brewing is popular among consumers. There are manyformats of single serve brewers on the market. These brewers aredesigned to quickly brew a single cup of coffee or tea. The coffee ortea grounds are sold in prepared, single serving portions.

Reusable devices for single serve brewers, such as devices with metal orsteal filters, may not suitable in some situations. For example, whenefficiency is required such as in a busy home, in an office environment,or in a waiting-room environment. Reusable devices require cleaning,which may be complicated by the tendency of beverage grounds to cakeinto the filter openings. Additionally, to accommodate cleaning ofreusable devices, the single serve brewer will be required to be placednear a source of water and a sink or drain. Provision of a sink or drainmay be impracticable.

BRIEF SUMMARY

In a first aspect, a basket for holding beverage grounds includes aframe. The frame includes a continuous rim that defines an opening at atop of the frame, a bottom portion that is closed, and a plurality ofspaced apart ribs that extend from the rim to a peripheral edge of thebottom portion. The bottom edge, plurality of ribs, and rim define aplurality of openings that facilitate fluid flow. A filter material ispositioned in the plurality of openings. A removable outer sleeve isformed on an outside surface of the frame. The outer sleeve isconfigured to cover at least the plurality of openings to therebyprovide an air-tight seal within the frame.

In a second aspect, a beverage package includes a flow wrap materialthat defines a plurality of sealed pockets, and a beverage basket forstoring beverage grounds positioned within each sealed pocket. Eachbeverage basket includes a frame. The frame includes a continuous rimthat defines an opening at a top of the frame, a bottom portion that isclosed, and a plurality of spaced apart ribs that extend from the rim toa peripheral edge of the bottom portion. The bottom edge, plurality ofribs, and rim define a plurality of openings that facilitate fluid flow.The beverage basket also includes a filter material positioned in theplurality of openings. A removable outer sleeve is formed on an outsidesurface of the frame configured to cover at least the plurality ofopenings to thereby provide an air-tight seal within the frame.

In a third aspect, a method for forming a beverage basket for holdingbeverage grounds includes forming a frame that includes a continuous rimthat defines an opening at a top of the frame, a bottom portion that isclosed, and a plurality of spaced apart ribs that extend from the rim toa peripheral edge of the bottom. The bottom portion, plurality of ribs,and rim define a plurality of openings that facilitate fluid flow. Afilter material is positioned in the plurality of openings. A removableouter sleeve is formed on an outside surface of the frame and isconfigured to cover at least the plurality of openings to therebyprovide an air-tight seal within the frame.

Other systems, methods, features and advantages of the invention willbe, or will become, apparent to one with skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description, be within the scope ofthe invention, and be protected by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a disposable beverage portion basket with packaging.

FIG. 2 illustrates a disposable beverage portion basket and lid.

FIG. 3 illustrates a disposable beverage portion basket with exemplarydimensions.

FIG. 4 illustrates use of a disposable beverage portion basket.

FIG. 5 illustrates an exemplary lid for a disposable beverage portionbasket.

FIG. 6 illustrates an exemplary package of multiple disposable beverageportion baskets.

FIG. 7A illustrates an exemplary filter medium side portion configuredto be molded into a basket.

FIG. 7B illustrates an exemplary filter medium bottom portion, ifneeded, configured to be molded to a bottom surface of a frame of abasket.

FIG. 7C illustrates an exemplary filter side portion and filter bottomportion molded to a basket.

FIG. 8A illustrates the placement of a logo on the exemplary lid.

FIG. 8B illustrates the placement of a logo of the basket.

FIG. 8C illustrates the placement of a logo on underside of the basket.

FIG. 9A illustrates a disposable beverage portion basket that defines agroove on a bottom portion.

FIG. 9B illustrates a disposable beverage basket that defines a grooveand indentation on a bottom portion.

FIG. 10A illustrates an exemplary cartridge with an annular ring used inconnection with the beverage basket of FIG. 9A.

FIG. 10B illustrates an exemplary cartridge with a button used inconnection with the beverage basket of FIG. 9B.

FIG. 11A illustrates a disposable beverage basket with a group ofoutwardly extending ledges;

FIG. 11B illustrates a disposable beverage basket with a group ofinwardly extending ledges

FIG. 12A illustrates stacking of disposable beverage baskets thatinclude outwardly extending ledges;

FIG. 12B illustrates stacking of disposable beverage portion basketsthat include inwardly extending ledges.

FIGS. 13A-13C illustrate perspective, side, and bottom views,respectively, of yet another beverage basket embodiment.

FIGS. 14A and 14B illustrate a first lid embodiment for covering thebeverage basket of FIGS. 13A-13C.

FIGS. 15A and 15B illustrate a second lid embodiment for covering thebeverage basket of FIGS. 13A-13C.

FIGS. 16A and 16B illustrate a basket and lid that twist lock together.

FIG. 17 illustrates a basket and lid formed together.

FIGS. 18A and 18B illustrates liquid distribution fins positioned on alower surface of an exemplary lid.

FIG. 19A illustrates application of a first exemplary sleeve embodimentover a beverage basket.

FIG. 19B illustrates application of a second exemplary sleeve embodimentover a beverage basket.

FIG. 19C illustrates a sealed beverage basket embodiment.

FIG. 20A illustrates a sealed beverage basket embodiment that includes atab for removing an outer sleeve.

FIG. 20B illustrates a sealed beverage basket embodiment that includes anotch for removing an outer sleeve.

FIG. 21A illustrates a beverage packet.

FIG. 21B illustrates a string of beverage packets.

DETAILED DESCRIPTION OF THE DRAWINGS

Single serve beverage brewing is popular among consumers due to theconvenience and flexibility that it provides. Many single serve beveragebrewers have entered the market. Traditional brewers typically producebetween four and twenty cups of beverage at a time. The beverage sits ona hot plate until it is consumed. As time passes, the taste of thebeverage may decline. Single serve brewing allows a consumer to enjoybeverages, such as coffee and tea, in an efficient fashion and without adecline in the taste profile of the beverage.

In FIG. 1, coffee or tea grounds for use in a single serving brewer maybe packaged in a disposable single use beverage package 100. Adisposable single use beverage package 100 may include a basket 110,which may be a permeable basket and barrier 112, which may be adisposable impermeable barrier.

The barrier 112 may have a first side 114 and a second side 116. Thefirst side 114 may include a score, a tab, a zip, an embedded string, orotherwise provide a means for assisting a user to open the barrier 112.The barrier 112 may be sealed at the second side 116 or other sides bygusseting, pinching, heat sealing, stapling, or otherwise. Alternativelyor additionally, the barrier 112 may be a shrink wrap barrier or a waxbarrier, among others.

The barrier 112 may be substantially resistant to the passage ofliquids, gases, and solids. For example, the barrier 112 may behermetically sealed to block moisture and oxygen from entering the pouchand to retain the aroma of the coffee. Additionally or alternatively,several baskets may be prefilled and packaged together in an egg cratetype configuration, a tube, or other packaging, to maintain freshnessduring shipping and storing. The barrier 112 may be made of materialssuch as foil laminate, metalized films, EVOH films, polyolefin basedmaterial, parafilm, plastics, and combinations of these, among others.

A user may open the package 100, for example, by tearing the barrier 112along the first side 114 to reveal the basket 110. The user may removethe basket 110 from the barrier 112 and place the basket 110 into asingle serve brewer. The basket 110 may be prefilled with grounds, oralternatively, the user may add grounds to the basket 110.

The basket 110 may be a single-wall permeable basket including a firstend 118, which may be reversibly closed or an open end, and a second end120, which may be a closed end. The basket 110 may be a cup shapedbasket and may be used with a lid 122. The basket 110 may also have aside wall 124 and a rim 126. The side wall 124 may connect the secondend 120 and the rim 126. The side wall 124 may include a frame 128 and afilter medium 130.

The frame 128 may provide structure, stability, and integrity to thefilter medium 130. The frame 128 may be formed by injection molding orby a different process suitable for manufacturing a rigid form around arelatively flexible filter medium. The frame 128 may be made of any oneof many commercially available materials, such as polystyrene,polyethylene, polypropylene, polyester, polyamide or Nylon, or othersynthetic or natural plastics or combinations thereof. The frame 128 maybe made from other materials such as a bio-based polymer, such aspolylaticacid (PLA), poly hydroxybutaric acid (PHA) or a starch basedpolymer. The frame 128 may be made of other materials known to thoseskilled in the art.

In FIG. 2, the side walls 124 of the basket 110 may be defined by theframe 128 and a filter medium 130. The filter medium 130 may be securedto the basket 110, for example, at the second end 120, the rim 126,and/or at that frame 128. The filter medium 130 may be secured forexample, by thermal bonding of the plastic used for the frame 128, orwith an adhesive, by crimping, by heat sealing, or any other way. Thefilter medium 130 may be secured in the frame 128 in insert-injectionmolding of the plastic frame around a filter medium insert. For example,a pre-die cut blank of filter medium may be placed on a mandrel whichhas channels around the shape of the pre die-cut blank. Molten plasticmay flow in and bond to the blank of the filter medium 130 duringinert-injection molding. The plastic may solidify into the frame 128,for example, upon cooling. Referring to FIGS. 7A-7C, in an alternativeembodiment the filter medium 700 and 705 may be first formed into agenerally cylindrical and tapered portion 700 and an optional bottomcircular filter medium 705 herein after referred to as the circularportion 705. The filter medium 700 and 705 may then be placed orinserted onto a mold for insert injection molding to form the basket 710with the filter media 700 and 705 supported by the frame of the basket710. The bottom end 715 of the frame of the basket 710 may besubstantially open and a circular filter portion 705 may cover the openportions.

The filter medium 130 may be a porous material and may be permeable toliquids and some oils. It may be formed of many materials, for example,non-woven materials such as polystyrene, polyethylene, polypropylene,polylactic acid, cellulosic fibers, polyhydroxyalkanoates, thermoplasticstarch, filter paper, other paper materials, polymer materials, acombination of these or any other material. The filter medium 130 mayalso be formed from a polymer or plastic filtration mesh, or microporousor apertured films made of various plastic materials, such aspolypropylene, Nylon 6 and high density polyethylene or other materialsknown to those skilled in the art. Alternatively, the filter medium 130may be formed from a bio-based polymer, such as polylatic acid (PLA),poly hydroxybutaric acid (PHA) or starch based polymer.

Characteristics of the filter medium 130 may be selected to meet thefiltration needs of different products, such as ground coffee, teapowders or leaves, or other brewed products. For example, the basisweight, thickness, strand count, mesh size, flow rate and strength ofthe filter medium 130 may be selected based on the product to be brewed.

The filter medium 130 may be compostable, biodegradable, recycled,and/or recyclable. If the filter medium 130 is a non-woven material, itmay have a greater resistance than, for example, a woven material or ametal filter. A non-woven filter medium 130 may retain water in thebasket for longer than, for example, a woven or metal filter. The lengthof time that the water is retained in the basket with the grounds mayinfluence the strength and therefore the taste profile of the resultingbeverage. This may be because a woven material or a metal material mayhave technological limitations on the size of the openings therethrough. A non-woven material may not have the same technologicallimitations. Therefore, the difference may be that, in a woven materialor metal material, the path of the water may be straight through thewall and in the non-woven material, the path may be indirect andconvoluted.

The basket 110 may include a lid 122. The lid 122 may include a rim 202and a cover 200. The cover 200 may be disposed below the rim 202 forsecure fitting with the basket 110. Alternatively, the cover 200 may notinclude a rim 202. The cover 200 may be made from a material that may bepunctured to allow a liquid to enter into the basket. For example, thecover 200 may be a material, such as a foil, film, coated film, ormultilayer laminate, which is sealed to or across the rim 126 of thepermeable basket 110 to maintain contents therein. The cover 200 maykeep dry contents dry, wet contents wet, and may maintain a freshness ofthe contents. The cover 200 may be formed of a plastic, metallic foil,filter material, thermoplastic starch, or a laminate or compositethereof.

The basket 110 may be dimensioned for use with a commercial single servecoffee brewer. FIG. 3 shows an exemplary basket 110. The basket 110 mayhave width of the open end 312, and a height 316. The open end 312 maybe, for example but not limited to, about 38-42 mm. The height 316 maybe, for example but not limited to, 38-42 mm. The rim 126 may have adimension 314 of, for example but not limited to, 3.5-5.5 mm. The frame128 may have a dimension 320 of, for example but not limited to, 5 mm,and a dimension 318 of, for example but not limited to 2 mm. Thesedimensions are merely exemplary and not limiting. The basket 110 mayalso have other dimensions or shapes, for example, dimensions thatpermit use in various single serve beverage machines.

In FIG. 4, a basket 110 may be prefilled with beverage grounds 414, forexample but not limited to, coffee or tea grounds. Alternatively oradditionally, the basket 110 may be loaded with beverage grounds 414immediately prior to use. If the basket 110 is prefilled with beveragegrounds 414 it may be sealed with a lid 122. Alternatively, if thepermeable basket 110 is not preloaded with beverage grounds 414, it maynot have a lid 122, additionally or alternatively; it may have aremovable lid 122, or otherwise.

During use, a user may open the barrier 112, take out the basket 110 andplace the basket 110 into a single serve beverage machine. A heatedliquid 410 may be received by the basket 110 through an opening in thecover 200 or otherwise. For example, during use, a preloaded basket 110may be placed inside a cartridge 400 for a single serve beveragemachine. The cartridge 400 may be reusable or disposable. During abrewing cycle, the cover 200 may be pierced by a probe 416 to admitheated liquid 410 into the basket 110. The heated liquid may interactwith the beverage grounds 414 creating a beverage medium. The beveragemedium 418 may flow through the filter medium 130 and exit through anopening in the cartridge 400.

As a second example, during use, an unloaded permeable basket 110 may beplaced inside a cartridge 400 for a single serve beverage machine. Thecartridge 400 may be reusable or disposable. The beverage grounds 414may be placed into the basket 110. A cover 200 may be attached tomaintain the contents of the basket 110. During a brewing cycle, thecover 200 may be pierced by a probe 416 to admit heated liquid 410 intothe basket 110. The heated liquid may interact with the beverage grounds414 creating a beverage medium. The beverage medium 414 may flow throughthe filter medium 130 and exit through an opening in the cartridge 400.Alternatively, no cover 200 may be required. In this case, the heatedliquid 410 will flow directly into the basket 110.

FIG. 5 illustrates one example of a lid 122 for a basket 110. The cover200 of the lid 122 may include an opening 500 for entry of a liquidprobe. The opening 500 may be a weakened portion of the material of thecover 200 which may give easily under the pressure of a probe.

In FIG. 6, unloaded tapered baskets 110 may be configured for efficientnesting. The baskets 110 may be sold nested in a stack or tube, whichmay be packed in a sleeve of plastic film, or otherwise. The unloadedbasket 110 may allow the end user to select a variety of beveragegrounds 414 for use in their single serve brewer. The end user may alsobe able to modify the amount of beverage grounds 414 for use in theirsingle serve brewer.

The components of the single use beverage package 100 may be selectedwith the intention of creating an environmentally friendly product. Forexample, the filter medium 130 may be made from a range of synthetic orbiodegradable, recycled or recyclable, or compostable materials such aspolyolefins, polylacticacid, cellulosics, polyhydroxyalkanoates,thermoplastic starch, a combination of these or other materials. Thebasket frame 128 material, cover 200 and barrier 112 may also be madeout of these materials or similar synthetic, biodegradable, recycled orrecyclable, or compostable materials which retain the properties ofstructural integrity (e.g., frame 128) and impermeability (e.g., barrier112).

While various embodiments of the embodiments have been described, itwill be apparent to those of ordinary skill in the art that many moreembodiments and implementations are possible that are within the scopeof the claims. For example, referring to FIGS. 8A-8C, logos 805 ofvarious configurations may be placed on the lid 122 (FIG. 9A), thebasket 110 (FIG. 8B), or the underside of the basket 110. The logos 805may also be printed on the filter medium 130. The logos 805 enable avendor to, for example, place descriptive information about the productthat is in the basket, such as whether the product is coffee or tea, atype of blend, and the like. Other information known to those skilled inthe art may also be printed.

FIGS. 9A-10B illustrate yet other embodiments of disposable beveragebaskets. FIG. 9A and FIG. 9B illustrate beverage basket embodimentsconfigured to control the positioning of the basket within a cartridgeor brewer. Referring to FIG. 9A, the beverage basket 900 (shown upsidedown) includes a frame 128 and filter material 903. The frame 128includes a rim 126, a bottom portion 120, and a group of ribs 906. Therim 126 defines an opening that corresponds to the top of the frame 128when the frame 128 is in an upright position. The rim 126 may becontinuous and have a circular shape, oval shape, or a different shape.The bottom portion 120 is a closed surface that corresponds to thebottom of the frame 128. The ribs 906 extend from the rim 126 to theedge of the bottom portion 120. The ribs 906, rim 126, and bottomportion 120 define a group of openings that facilitate fluid flow, suchas coffee, tea, or a different beverage.

The bottom portion 120 defines a groove 905 and/or an indentation 907(See FIG. 9B). The groove 905 may extend in a continuous manner alongand inward of the edge of the bottom portion 120. The groove 905 and/orindentation 907 are configured to cooperate with a complementaryfeature, e.g., a protruded needle in the bottom of a cartridge or brewerto accurately position the basket 900 within the cartridge or brewer.That is the groove 905 and/or indentation 907 are configured to meshwith a complementary feature of the cartridge or brewer to controlalignment of the basket 900 so that the outer walls of the basket 900are not up against inner walls of the cartridge or brewer during use,which could otherwise limit fluid flow through the basket 900.

FIG. 10A and FIG. 10B, illustrate exemplary cartridges 1000 and 1015with alignment features. The same alignment features may be provided ina brewer independently of a cartridge. Referring to FIG. 10A, thefeature corresponds to an annular ring 1005. The annular ring 1005 maybe suspended within the cartridge by one or more bridge members 1007 tofacilitate fluid flow around the annular ring 1005. The annular ring1005 may be sized to fit within the groove 905 of the beverage basket900. In a brewer implementation, the annular ring 1007 may be formed ina portion of the brewer configured to receive the beverage basket 900.In other implementations, the annular ring 1005 and one or more bridgemembers 1007 may correspond to a separate component configured to fitsubstantially near the bottom of the cartridge 1000 or brewer and tomaintain a distance between sidewalls of the cartridge 1000 or brewer.

Referring to FIG. 10B, the feature corresponds to a button 1017. Thebutton 1017 may be sized to fit within the indentation 907, describedabove. The button 1017 may be supported by a bridge member 1019 toenable fluid flow around the button 1017. In a brewer implementation,the button 1017 may be formed in a portion of the brewer configured toreceive the beverage basket 900. In other implementations, the button1017 and bridge member 1019 may correspond to a separate componentconfigured to fit substantially near the bottom of the cartridge 1015 orbrewer and to maintain a distance between sidewalls of the cartridge1015 or brewer.

FIG. 11A and FIG. 11B illustrate beverage basket embodiments 1100 and1150 configured to be stacked. Referring to FIG. 11A, the beveragebasket 1100 includes a frame 128 and filter material 903, as describeabove. For example, the frame includes a rim 126, a bottom portion 120,and a group of ribs 906. The rim 126 defines an opening that correspondsto the top a top of the frame 128. The rim 126 may be continuous andhave a circular shape, oval shape, or a different shape. The bottomportion 120 is a closed surface that corresponds to the bottom of theframe 128. The ribs 906 extend from the rim 126 to the edge of thebottom portion 120. The ribs 906, rim 126, and bottom portion 120 definea group of openings that facilitate fluid flow, such as coffee, tea, ora different beverage.

Each rib 906 includes a ledge 1105 and 1110 (FIG. 11B) positioned in acenter region. The ledges 1105 and 1110 are configured to limit anamount by which respective baskets 1100 and 1150 are insertable into oneanother. Limiting the insertion amount results in a space 1210 (FIG.12B) between respective bottoms 120 of the baskets 1100 and 1150. Thespace 1210 may be sized to facilitate storage of beverage grounds, suchas coffee ground, tea grounds, or other grounds, which the baskets 1100and 1150 are stacked. That is, the position of the ledges 1105 and 1210along the ribs 906 may be configured to result in a desired amount ofspace 1210 between respective baskets. Thus, several baskets may beadvantageously filled with grounds and then stacked to save space.

In some configurations, the ledge 1105 extends outwardly away from thecenter of the basket. (See FIG. 11A). Referring to FIG. 12A, in thisconfiguration, the ledge 1105 of a top basket 1205 rests upon the rim126 of a lower basket 1207. In this regard, the distance betweenopposing ledges 1105 (i.e., ledges 1105 on opposite sides of the basket1100) may be equal to about the inner diameter of the rim 126.

In other configurations, the ledge 1110 extends inwardly towards thecenter of the basket. (See FIG. 11B). Referring to FIG. 12B, in thisconfiguration, the bottom portion 120 of the top basket 1205 rests uponthe ledge 1110 of the lower basket 1207. In this regard, the distancebetween opposing ledges 1110 (i.e., ledges 1105 on opposite sides of thebasket 1100) may be equal to about the outer diameter of the bottomportion 120.

FIGS. 13A-13C illustrate perspective, side, and bottom views,respectively, of yet another beverage basket embodiment 1300. Thebeverage basket 1300 is configured to be placed into a brewer (notshown) without the need for a cartridge 400. Such brewers typicallyinclude a receiving member sized to receive a basket with a similaralthough not identical shape. A protruded membrane-piercing needle ispositioned in the lower portion of the receiving member and isconfigured to pierce the lower portion of a typical plastic cup (e.g., agenerally cylindrically shaped cup with a flat and closed bottomsurface) so as to facilitate fluid flow out of the basket, through theneedle, and then into a cup.

The beverage basket embodiment 1300 includes a frame 1305. The frame1305 includes a rim 1310, a bottom portion 1315, and a group of ribs1320. The rim 1310 defines an opening that corresponds to the top of theframe 1305 when the frame 1305 is in an upright position. The rim 1310may be continuous and have a circular shape, oval shape, or a differentshape. The bottom portion 1315 is a closed surface that corresponds tothe bottom of the frame 1305. The ribs 1320 extend from the rim 1310 tothe edge of the bottom portion 1315. The ribs 1320, rim 1310, and bottomportion 1315 define a group of openings that facilitate fluid flow, suchas coffee, tea, or a different beverage. The beverage basket embodiment1300 also includes a filter material that covers the openings, such asany of the filter materials described above, which is not shown in thisinstance for clarity.

A first portion 1325 (FIG. 13C) of the bottom portion 1315 issubstantially flat. Whereas a second portion 1330 of the bottom portion1315 defines an indentation 1335, which can be either fully enclosed orsemi enclosed. The first portion 1325 may occupy ¾ or more of thesurface area of the bottom portion 1315. The second portion 1330 mayoccupy the remaining area. The indentation 1335 is sized so that whenthe basket 1300 is inserted into the receiving member, themembrane-piercing needle fits within the indentation 1335 and does notpierce the bottom portion 1315. For example, a depth D of theindentation 1335 relative to the lower surface of first portion 1325 ofthe bottom surface may be, for example but not limited to, about 0.388″.The width of the indentation 1330 may be, for example but not limitedto, about 0.287″, and the indentation 1335 may be offset towards a sideedge of the bottom portion 1315, which corresponds to the location ofthe membrane-piercing needle in some brewer implementations. However,the indentation 1335 may be located in a different location when themembrane-piercing needle is positioned differently. Limiting the spaceoccupied by the indentation 1335 (i.e., maximizing the space occupied bythe first portion) results in more space within the basket 1300 forgrounds, such as coffee grounds. This in turn facilitates the productionof stronger blends.

FIGS. 14A-16B illustrate various exemplary lids for covering thebeverage basket embodiment 1300. The respective lids are configured toselectively substantially seal the opening defined at the top of theframe 1305. FIGS. 14A and 14B illustrate a first exemplary lid 1400. Thelid 1400 includes an opening 1402 in a center region through which aliquid flows into the basket 1300. The lid 1400 also includes an annularring 1405 configured to be friction fit against an inner surface of therim 1310 of the frame 1305 to thereby form a seal between the lid 1400and the beverage basket 1300. That is, a seal between the outer surfaceof the annular ring 1405 and the inner surface of the rim 1310. Thediameter of the annular ring 1405 may be sized to provide a tight fitbetween the lid 1400 and the basket 1300 while still facilitatingremoval of the lid 1400.

FIGS. 15A and 15B illustrate a second exemplary lid 1500. The lid 1500includes an opening 1502 in a center region through which a liquid flowsinto the basket 1300. The lid 1500 includes a sidewall 1505 configuredto be snap fit over an outer edge of the rim 1310. In other words, theseal between the lid 1500 and the beverage basket 1300 is formed betweenthe inner surface of the sidewall 1505 and the outer surface of the rim1310. The diameter of the sidewall 1505 may be sized to provide a tightfit between the lid 1500 and the basket 1300 while still facilitatingremoval of the lid 1500.

FIGS. 16A and 16B illustrate another exemplary beverage basket 1600 andlid 1610. The beverage basket 1600 includes the features of the beveragebasket 1300 described above. However, the rim 1605 defines one or morecutouts 1612. The lid 1610 includes one or more tracks 1615 configuredto cooperate with the one or more cutouts 1612 to facilitate twistlocking of the lid 1610 to the beverage basket 1600. In this regard, thethickness of the rim 1605 may gradually increase with a distance awayfrom the cutouts 1612 so that the tightness between the lid 1610 and thebeverage basket 1600 increases with further twisting of the lid 1610.

The configurations above may be varied. For example, as illustrated inFIG. 17, the basket 1700 and lid 1705 shown in FIG. 14 may be formedtogether so that in an open configuration the lid 1705 is attached tothe basket 1700. The lid 1705 may then be folded over the basket 1700 toclose the top opening of the basket 1700 defined by the rim 1710. Acutout 1715 may be formed in the rim 1710 to expose an underside of thelid 1705 when the lid 1400 is in the closed configuration. The cutout1715 facilitates removal of the lid 1705 from the basket 1700.

As illustrated in FIGS. 18A and 18B, liquid distribution fins 1810 maybe formed on the underside of the lid 1805. During operation, liquidflowing into the lid opening will, through capillary pressure, be drawnover the liquid distribution fins 1810 and then drop onto the grounds inthe basket 1800. The liquid distribution fins 1810 distribute the liquidover a larger portion of the grounds in the basket 1800 than would occurwithout the use of fins 1810. This in turn facilitates more even brewingof the beverage. It is understood that the shape and number of fins 1810are only exemplary.

FIGS. 19A-20B illustrate a sealed beverage basket 1900 (FIG. 19C) andoperations for forming the same. The sealed beverage basket 1900includes a beverage basket wrapped in an outer sleeve that is made of agas barrier material, such as aluminum foil, coated monolayer plasticfilms, multi-layer laminates comprising of different plastic, aluminumfoil, metalized plastic, metalized paper and coated films, which acts asa high gas barrier to gasses such as nitrogen (N₂), carbon-dioxide (CO),Oxygen (O₂) and other aroma organic volatiles. The outer sleeve is formfit to the beverage basket, which results in a smaller storagefootprint. That is, the sealed beverage basket 1900 requires less spacethan some of the other embodiments.

The beverage basket may correspond to any of the described beveragebasket embodiments. For example, the beverage basket may correspond tothe basket 110 of FIG. 1. In this regard, the basket 110 includes aframe and filter medium, as described above. The frame includes a rim, abottom portion, and a group of ribs. A lid 200 may be placed on the topof the frame 128 to secure contents within the frame 128.

FIG. 19A illustrates a first exemplary embodiment of an outer sleeve1905 that may be placed around the outside surface of the basket 110 andsubsequently form fit to the basket 110 to thereby provide a sealedbeverage basket 1900. The outer sleeve 1905 is configured to cover atleast the openings in the basket 110 through which fluid flows tothereby provide an air-tight seal within the basket 110. The air-tightseal preserves the freshness of contents stored within the basket 110.

In a pre-form fit stage, the sidewall of the outer sleeve 1905 may betapered and the diameter sized to facilitate sliding of the basket 110within the outer sleeve 1905. The diameter along a top edge of the outersleeve 1905 may be sized to prevent the outer sleeve 1905 from extendingpassed the rim of the basket 110. The bottom of the outer sleeve 1905may be opened or closed.

After sliding the basket 110 into the outer sleeve 1905, an inert gas,such as nitrogen, may be injected into the interior of the basket 110 toflush out ambient air. At the same time, heat may be applied to outersleeve 1905 to cause the outer sleeve 1905 to shrink tightly around thebasket 110 to thereby form an air-tight seal that prevents ambient airfrom entering the basket 110.

In some implementations, the outer sleeve 1905 may be configured tocover other areas of the basket 110. For example, the outer sleeve 1900may cover a portion 1920 of the lid 200, as illustrated in FIG. 19C. Inthis case, the diameter of the top edge of the outer sleeve 1905 may besized to allow the sleeve 1905 to slide above the rim in the pre-formfit stage. This allows the sleeve to fold over the lid 200 during theform fitting process, which further secures the lid 200 to the frame ofthe basket 110 and provides a means for detection of tampering with thecontents stored within the basket 110. For example, a torn outer sleeve1905 may evince tampering with the contents of the sealed beveragebasket 1900.

FIG. 19B illustrates a second exemplary embodiment of an outer sleeve1910 that may be placed around the outside surface of the basket 110 andsubsequently form fit to the basket 110. Like the first outer sleeveembodiment 1905, the second outer sleeve embodiment 1910 is configuredto cover at least the openings of the basket 110 through which fluidflows to thereby provide an air-tight seal within the basket 110. Theair-tight seal preserves the freshness of contents stored within thebasket 110. In some implementations, the outer sleeve 1910 may beconfigured to cover other areas of the beverage basket 1900, such as aportion 1920 of the lid 200, which may provide the advantageous featuresdescribed above.

In the second embodiment, the outer sleeve 1910 is configured to bewrapped around the frame of the basket 110, as illustrated in FIG. 19B.In this regard, the outer sleeve 1910 is initially separated at firstand second edges 1912 and is provided with an overlap amount, asillustrated by the dashed line 1915 in FIG. 19B. The first and secondedges 1912 overlap one another when the outer sleeve 1910 is wrapped. Anadhesive may be applied to one or both edges 1912 to facilitate joiningof the edges. The adhesive may be a food grade peelable pressuresensitive adhesive that does not contaminate beverage grounds storedwithin the basket 110. For example, the adhesive can be acrylic basedpressure sensitive adhesives. In some implementations, the edges 1912may be joined through other suitable means, such as ultrasonic weldingand the like.

The second outer sleeve embodiment 1910 may be cut from a sheet ofsleeve material. Prior to cutting, graphics, labels, and the like may beprinted on the sleeve material. This advantageously provides for asealed beverage basket 1900 that includes graphics, labels, etc. on anoutside surface. These in turn facilitate, for example, easydetermination of the contents stored within the beverage basket 110, themanufacturer of the beverage basket, an expiration date, or any otherdesired information.

As illustrated in FIGS. 20A and 20B, in some implementations, the outersleeve 1905, 1910 includes a top portion 2005 configured to completelycover the lid 200. The top portion 2005 may be formed from the samematerial as the rest of the outer sleeve 1905, 1910. For example, thefirst outer sleeve embodiment 1905 may be configured to have a closedtop that corresponds to the top portion 2005 and may be configured(i.e., sized) to slide over the top of the basket 110 rather than thebottom. Alternatively, the top portion 2005 may be a separate portionjoined to the rest of the outer sleeve 1905, 1910 via any of the joiningprocesses described above, or different joining process. For example,the top portion may be joined via an adhesive, ultrasonic welding, or adifferent joining process.

In some implementations, the top portion 2005 may include a tab 2000(FIG. 20A) or notch 2010 (FIG. 20B) to facilitate easy removal of theouter sleeve 1905, 1910 from the basket 110. In implementations that donot include a top portion 2005, the outer sleeve portion that covers theopenings in the beverage basket may define the tab 2000 and/or notch2010.

FIG. 21A illustrates an exemplary beverage packet 2100 that may be usedin connection with any of the basket embodiments described above. Thebeverage packet 210 is made from a flow wrap material that may beutilized to define a number of beverage packets 2100. Each beveragepacket 2100 may include a sealed beverage basket, such as the sealedbeverage basket 1900, described above. The flow wrap material mayinitially correspond to a tube closed at one end and with a lengthsuited for packaging a desired number of sealed beverage baskets 1900.

In operation, a first sealed beverage basket 1900 is inserted into thetube. The tube is then sealed above the sealed beverage basket 1900 toform a first beverage packet 2100 that holds one sealed beverage basket1900. A second sealed beverage basket 1900 is then inserted at the openend of the tube and sealed into the tube to provide a second beveragepacket 2100. The operations continue until the desired number ofbeverage packets 2100 is obtained. The tube may be perforated betweenbeverage packets 2100 to facilitate easy separation of the beveragepackets 2100. The entire tube of beverage packet 2100 may be stored in acontainer 2105 for distribution and storage.

Accordingly, it will be apparent to those of ordinary skill in the artthat many more embodiments and implementations are possible that arewithin the scope of the claims. Moreover, the described embodiments maybe combined into new embodiments that provide any of the benefitsdescribed herein. Therefore, the embodiments described are only providedto aid in understanding the claims and do not limit the scope of theclaims.

The invention claimed is:
 1. A sealed beverage basket for holdingbeverage grounds comprising: a frame having an outside surface whichincludes: a continuous rim that defines an opening at a top of theframe; a bottom portion that is closed; a plurality of spaced apart ribsthat extend from the rim to a peripheral edge of the bottom portion,wherein the bottom edge, plurality of ribs and rim define a plurality ofopenings that facilitate fluid flow; a filter material positioned in theplurality of openings, the filter material formed of a same plasticmaterial as the frame; a lid member that covers the opening at the topof the frame to thereby secure the beverage grounds within the frame;and a removable, unitary and pre-formed outer sleeve shrink-fitted tothe outside surface of the frame to cover at least the plurality ofopenings to thereby provide a form-fitted sleeve about the frame and anair-tight seal within the frame; wherein the outer sleeve is apre-formed and discontinuous sleeve that includes first and secondoverlapping edges joined via an adhesive, said discontinuous sleevewrapped about and shrink-fitted to the outside surface of the frameafter the edges are joined to thereby form an air-tight seal within theframe.
 2. The basket according to claim 1, wherein the outer sleeve isformed at least partially over the lid member.
 3. The basket accordingto claim 1, wherein the adhesive is a food grade adhesive.
 4. The basketaccording to claim 1, wherein the outer sleeve defines a tab or notchthat facilitates peeling of the outer sleeve from the frame.
 5. Thebasket according to claim 1, wherein the removable outer sleeve isremovable from the frame thereby uncovering at least the plurality ofopenings without removing the lid member.
 6. An air-tight beveragepackage comprising: a tube of unitary flow wrap material that defines aplurality of sealed pockets; and a sealed beverage basket for storingbeverage grounds, a respective beverage basket positioned within eachsealed pocket, wherein each beverage basket includes: a frame thatincludes: a continuous rim that defines an opening at a top of theframe; a bottom portion that is closed; and a plurality of spaced apartribs that extend from the rim to a peripheral edge of the bottomportion, wherein the bottom edge, plurality of ribs and rim define aplurality of openings that facilitate fluid flow; a filter materialformed of a same plastic material as the frame and positioned in theplurality of openings; a lid member that covers the opening at the topof the frame to thereby secure the beverage grounds within the frame;and a removable, unitary and pre-formed outer sleeve shrink-fitted to anoutside surface of the frame configured to cover at least the pluralityof openings to thereby provide a form-fitted sleeve about the frame andan air-tight seal within the frame; wherein the outer sleeve is apre-formed and discontinuous sleeve that includes first and secondoverlapping edges joined via an adhesive, said discontinuous sleevewrapped about and shrink-fitted to the outside surface of the frameafter the edges are joined to thereby form an air-tight seal within theframe.
 7. The beverage package according to claim 6, wherein the tube offlow wrap material is perforated between adjacent pockets to facilitatecontrolled separation of the pockets.
 8. The beverage package to claim6, wherein the outer sleeve is formed at least partially over the lidmember.
 9. The beverage package according to claim 6, wherein theadhesive is a food grade adhesive.
 10. The beverage package according toclaim 6, wherein the outer sleeve defines a tab that facilitates peelingthe outer sleeve from the basket.
 11. The beverage package according toclaim 6, wherein the outer sleeve defines a notch that facilitatespeeling the outer sleeve from the basket.
 12. A method for forming anair-tight beverage basket for holding beverage grounds comprising:forming a frame that includes a continuous rim that defines an openingat a top of the frame, a bottom portion that is closed, and a pluralityof spaced apart ribs that extend from the rim to a peripheral edge ofthe bottom, wherein the bottom portion, plurality of ribs and rim definea plurality of openings that facilitate fluid flow; positioning a filtermaterial in the plurality of openings, said filter material of the sameplastic material as the frame; providing a lid member that covers theopening at the top of the frame thereby securing the beverage groundswithin the frame; and forming a removable outer sleeve on an outsidesurface of the frame configured to cover at least the plurality ofopenings to thereby provide an air-tight seal within the frame; whereinforming the outer sleeve comprises: providing a preformed, unitarysleeve configured to slide over the frame; injecting an inert gas intoan interior space of the frame to thereby remove ambient air from withinthe interior space; and simultaneously applying heat to the outer sleeveto thereby shrink the outer sleeve onto and around the frame; whereinthe outer sleeve is a wrap-around sleeve with first and second ends, andthe method further comprises: applying an adhesive on at least one ofthe first and second ends; wrapping the outer sleeve around the basketuntil one end overlaps the other end to thereby join the opposite ends;injecting an inert gas into an interior space of the frame to therebyremove ambient air from within the interior space; and simultaneouslyapplying heat to the outer sleeve to thereby shrink the outer sleevearound the frame.
 13. The method according to claim 12, wherein theadhesive is a food grade adhesive.
 14. The method according to claim 12,wherein the outer sleeve defines a tab or notch that facilitates peelingthe outer sleeve from the frame.
 15. The method according to claim 12further comprising forming a plurality of sealed pockets using a tube ofa unitary flow wrap material, wherein the plurality of sealed pocketseach contains a sealed beverage basket with removable outer sleeve andlid member.
 16. The method according to claim 12 further comprising:inserting the beverage basket into a tube of a unitary flow wrapmaterial; sealing the tube of flow wrap material at a top side of theframe; and sealing the tube of flow wrap material at a bottom side ofthe frame thereby forming a sealed pocket of the tube of flow wrapmaterial.